Bracketless caliper

ABSTRACT

A device comprising: a caliper comprising: one or more piston bores housing a piston; an outboard pad retainer; a bridge; and a shoulder; wherein the caliper is attached directly to a knuckle of an automobile via the shoulder.

FIELD

The present teachings generally relate to a caliper that is directlyattached to a knuckle and/or support device and is free of a supportbracket.

BACKGROUND

The present teachings are predicated upon providing an improved discbrake system for use with vehicles. For example, the disc brake systemmay be used with almost any vehicle (e.g. car, truck, bus, train,airplane, or the like). Alternatively, the disc brake system may beintegrated into assemblies used for manufacturing or other equipmentthat require a brake such as a lathe, winder for paper products orcloth, amusement park rides, wind turbines, the like, or a combinationthereof. However, the present teachings are most suitable for use with apassenger vehicle (i.e. a car, truck, sports utility vehicle, or thelike). Typical disc brake systems have either a floating caliper or afixed caliper as discussed below.

Generally, a floating caliper braking system includes a rotor, a caliperbody, a support bracket, and ah inboard brake pad and an outboard brakepad located on opposing sides of the rotor. The caliper body furtherincludes a bridge, one or more fingers, and a piston bore. The pistonbore houses a piston. The piston bore has a bore axis that the pistonmoves along during a brake apply and a brake release. The piston boremay include a fluid inlet, a closed wall, a front opening, and acylindrical side wall that has a seal groove located near the frontopening. Typically, the fluid inlet is located in the closed wall of thepiston bore so that when pressure is applied the fluid will flow intothe piston bore. During a pressure apply the fluid will push the pistontowards the front opening and into contact with a brake pad and then thebrake pad into contact with a rotor. The caliper housing, upon the brakepad contacting the rotor, moves so that the one or more fingers contactthe opposing brake pad and then move the opposing brake pad into contactwith the opposing side of the rotor so that a braking force is created.Some examples of floating style disc brakes may be found in U.S. Pat.Nos. 3,260,332; 3,997,034; 4,342,380; 4,881,194; 4,716,994; and7,357,228 all of which are incorporated by reference herein for allpurposes.

Generally, a fixed caliper braking system includes a rotor, a caliperbody, a support bracket, and an inboard brake pad and an outboard brakepad located on opposing sides of the rotor. The caliper body includes abridge, an inboard piston bore having an inboard piston, and an outboardpiston bore having an outboard piston. The outboard piston and theinboard piston are located on opposite sides of the rotor so that duringa brake apply both pistons move each respective brake pad into contactwith the respective sides of the rotor. During a brake apply, thecaliper remains generally static as the inboard piston and the outboardpiston travel toward each other moving the respective brake pad intocontact with opposing sides of the rotor so that a braking force iscreated. Some examples of fixed disc brake systems may be found in U.S.Pat. Nos. 5,099,981 and 6,387,595 all of which are incorporated byreference herein for all purposes.

Examples of additional brake systems are found in and U.S. PatentApplication Publication Nos. 2004/0100058, 2004/0188188, and2006/0124404. However, some of these systems include multiple parts tofunction, are heavy; or both, thus, adding weight to the overall weightof vehicle, which affects the overall fuel economy of the vehicle.

It would be attractive to have a brake system that is reduced in mass sothat the overall mass of the system in which it is installed is reduced.It would be attractive to have a device with a reduced mass and areduced number of parts, while maintaining braking performance. What isneeded is a device that reduces the mass and/or number of parts whilemaintaining a low taper wear for the brake pads, low disc thicknessvariation (DTV) of the rotor and low brake torque variation (BTV) of thebrake pads so that the operator and/or passengers do not experience anyadverse effects on the system.

SUMMARY

The present teachings meet one or more of the present needs byproviding: a device comprising: a caliper comprising; one or more pistonbores housing a piston; an outboard pad retainer; a bridge; and ashoulder; wherein the caliper is attached directly to a knuckle of anautomobile via the shoulder.

The present teachings provide a disc brake system comprising: a calipercomprising; one or more piston bores housing a piston; an outboard padretainer; a bridge having a rail so that an inboard brake pad movesalong the rail during a brake apply, a brake off, or a conditionthereof; an inboard pad retainer; and a shoulder including one or moreattachment features that extend through the shoulder; a rotor connectedto a knuckle of an automobile, wherein the bridge extends over therotor; wherein the caliper is attached directly to the knuckle via theshoulder and the caliper is free of attachment to a support bracket; andwherein the one or more attachment features are larger than one or morefasteners so that the one or more fasteners when placed in the one ormore attachment features are capable of moving, the caliper whenattached is capable of moving, or both.

The teachings herein surprisingly solve one or more of these problems byproviding a device having a brake system that is reduced in mass so thatthe overall mass of the system in which it is installed is reduced. Thepresent teachings are a device having a reduced mass and a reducednumber of parts, while maintaining braking performance. The presentteachings are a device that reduces the mass and/or number of partswhile maintaining a low taper wear for the brake pads, low discthickness variation (DTV) of the rotor and low brake torque variation(BTV) of the brake pads so that the operator and/or passengers do notexperience any adverse effects on the system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates one possible embodiment of the disc brake system;

FIG. 2 illustrates another possible embodiment of the disc brake system;

FIG. 3 illustrates yet another possible embodiment of the disc brakesystem;

FIG. 4 illustrates a cross-sectional view along line I-I of FIG. 2;

FIG. 5 illustrates a close-up view of a connection of FIG. 4;

FIG. 8 illustrates a cross-sectional view along line II-II of FIG. 3;

FIG. 7 illustrates one possible embodiment of the disc brake system;

FIG. 8 illustrates one possible embodiment of a brake pad that may beused with the disc brake system;

FIG. 9 illustrates a rear perspective view of the disc brake system ofFIG. 7 including a rotor;

FIG. 10A illustrates a brake apply with new brake pads;

FIG. 10B illustrates a brake apply with worn brake pads;

FIG. 10C illustrates a brake off;

FIG. 11 illustrates a cross-sectional view of a shoulder and knuckleincluding a tab; and

FIG. 12 illustrates one possible tab that may be used with the discbrake system.

DETAILED DESCRIPTION

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the teachings, its principles,and its practical application. Those skilled in the art may adapt andapply the teachings in its numerous forms, as may be best suited to therequirements of a particular use. Accordingly, the specific embodimentsof the present teachings as set forth are not intended as beingexhaustive or limiting of the teachings. The scope of the teachingsshould, therefore, be determined not with reference to the abovedescription, but should instead be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. The disclosures of all articles and references,including patent applications and publications, are incorporated byreference for ail purposes. Other combinations are also possible as willbe gleaned from the following claims, which are also hereby incorporatedby reference into this written description.

The present teachings relate to a brake assembly. The brake assembly maybe any brake assembly that provides a friction force during a brakeapply. Preferably, the brake assembly is attached to a knuckle of avehicle and/or a support device so that the brake assembly may be usedto create a friction force during a brake apply. More preferably, thebrake assembly is free of a support bracket for attaching a caliper to aknuckle or a support device. Even more preferably, a shoulder of thecaliper is attached directly to a support device (e.g., part of amachine or a knuckle). The brake assembly as taught herein may be a discbrake system. The disc brake system may be used in conjunction with alathe, winder for paper products or cloth, amusement park rides, windturbines, the like, or a combination thereof (i.e., the brake assemblymay be attached to a support device of one or more of these devices sothat it may be used to create a braking force). However, the disc brakesystem is preferably most suitable for use with a passenger vehicle(i.e. a car, truck, sports utility vehicle, or the like).

The disc brake system includes a caliper, a rotor, and two opposingbrake pads. The caliper may be any caliper that may be attached directlyto a knuckle and/or support device and create a braking force. Thecaliper may be any caliper that may be free of a support bracket forconnection to a support device. The caliper may be free of connection toa support bracket. The caliper includes a shoulder, one or more pistonbores, one or more pistons in the one or more piston bores, an outboardpad retainer, a bridge connecting the outboard pad retainer to the oneor more piston bores, and optionally an inboard pad retainer connectedto the bridge and/or the piston bore.

The outboard pad retainer may be any device that assists a brake pad inproducing a friction force during a brake apply. The outboard padretainer may be any device that holds a brake pad, a friction plate,friction material, a pressure plate, or a combination thereof(hereinafter “brake pad”). A brake pad may be permanently attached tothe outboard pad retainer. A brake pad may foe removably attached to theoutboard pad retainer. The outboard pad retainer may be connected to oneor more rails of the bridge by one or more rail attachments. Theoutboard pad retainer may be movable. The outboard pad retainer may bemoved by an outboard piston located in an outboard piston bore. Theoutboard pad retainer may attach the brake pact to a piston so that thepiston and brake pad move in unison. The brake pad may be supported onthe piston by the outboard pad retainer so that the outboard padretainer is free of attachment to the bridge. The outboard pad retainermay move along an axial direction with respect to a piston bore so thata friction force may be created. The outboard pad retainer may movealong the bridge. Preferably, the outboard pad retainer is fixed. Theoutboard pad retainer may be a unitary piece extending from the bridge.The outboard pad retainer and the bridge may be formed together. Theoutboard pad retainer may remain static during a brake apply withrespect to the bridge of the caliper. For example, the entire calipermay move and thus the outboard pad retainer may move with the caliper;however, the outboard pad retainer remains static relative to thebridge. The outboard pad retainer may include a sufficient amount offingers so that a brake force may be created during a brake apply. Theoutboard pad retainer may have 1 or more fingers, 2 or more fingers, or3 or more fingers. The outboard pad retainer may form an angle with thebridge and/or the piston bore axis. The outboard pad retainer may form asufficient angle with the bridge, a plane substantially parallel to thebridge, the piston bore axis, or a combination thereof so that theoutboard pad retainer assists in creating a brake apply. The outboardpad retainer may form substantially a right angle with the bridge.Preferably, the outboard pad retainer forms an angle of about 80 degreesor more, about 90 degrees or more, about 95 degrees or mores about 100degrees or more, or even about 105 degrees or more with the bridge, thepiston bore axis, or both. The outboard pad retainer may form an angleof about 150 degrees or less, about 135 degrees or less, or about 125degrees or less with the bridge, the piston bore axis, or both.

The bridge may be any device that connects the outboard pad retainerwith a piston bore, an inboard pad retainer with a piston bore, a pistonbore to an opposing piston bore, or a combination thereof. The bridgemay attach two opposing portions of the caliper together. The bridge mayfoe any device that extends over a rotor. The bridge may be any devicethat assists in creating a brake apply. The bridge may include a rail.

The rail may be any device that allows one or more part of the device tomove so that a brake apply is created. The rail may be any device sothat the outboard pad retainer, the inboard pad retainer, an inboardbrake pad, an outboard brake pad, or a combination thereof may moveduring a brake apply. The rail may be located at any ideation along thebridge. The rail may be integrally formed in a surface of the bridge.The rail may extend out from a surface of the bridge. The rail may be agroove that is connected with a rail attachment of the outboard padretainer, the inboard pad retainer, an inboard brake pad, an outboardbrake pad, or a combination thereof. The rail may extend along all or aportion of the bridge. The rail may be configured so that the rail andrail attachment form a mating relationship. The rail may be anyconfiguration so that a rail attachment may move along the rail. Therail may be any configuration so that a rail attachment may not beremoved from the rail without disassembling all or a portion of the railand/or the rail attachment. The rail may be configured so that a brakepad is directly attached to the rail so that the brake pad slidesaxially along the rail during a brake apply. The rail may be “T-shaped”cavity, a “T-shaped” projection, an “L-shaped” projection, a bail shapedcavity with a thin post shaped opening region, a larger inner cavitywith a thinner opening, a bar located on an outside of the bridge, or acombination thereof. The bridge may be free of a rail. For example, pinsmay extend axially, relative to the piston bore, adjacent to the bridgefor supporting and/or assisting in movement of one or more brake pads,the outboard pad retainer, the inboard pad retainer, or a combinationthereof. Preferably, the bridge supports the inboard pad retainer andincludes a rail so that the inboard pad retainer may move along thebridge during a brake apply via a rail attachment.

The rail attachment and the rail may have any relationship so that therail retains the rail attachment and allows the pad retainers (i.e., theinboard pad retainer, the outboard pad retainer, or both), the brakepads, or both to move along the rail. The rail attachment may have anyshape so that the rail attachment attaches to the rail and allows thepad retainers, the brake pads, or both to move along the rail. The railattachment may be “T-shaped,” a ball and post shaped, have a larger headand smaller body that extends out of the rail, a book, a “C-shape,” amating shape to a rail, or a combination thereof. The pad retainers maybe connected to the caliper in any manner so that as one or more pistonsextend out of the one or more piston bores the pad retainers move thebrake pads to create a friction force.

The inboard pad retainer may be any device that holds a brake pad, afriction plate, friction material, a pressure plate, or a combinationthereof (hereinafter “brake pad”). The inboard pad retainer may be anypart, that assists in creating a braking force during a brake apply. Thecaliper may be free of an inboard pad retainer. The inboard pad retainermay assist in moving a brake pad during a brake apply. A brake pad maybe permanently attached to the inboard pad retainer. A brake pad may beremovably attached to the inboard pad retainer. The inboard pad retainermay be fixed. Preferably, the inboard pad retainer may be movable. Theinboard pad retainer may be moved by an inboard piston located in aninboard piston bore. The inboard pad retainer may attach the brake padto a piston so that the piston and brake pad move in unison. The brakepad may be supported on the piston by the inboard pad retainer so thatthe inboard pad retainer is free of attachment to the bridge. Forexample, an inboard pad retainer may be a clip that attaches the brakepad to the piston. The inboard pad retainer may move along an axialdirection, with respect to a piston bore, so that a friction force maybe created. The inboard pad retainer may move along the bridge. Theinboard pad retainer may be a unitary piece extending from the bridge.The inboard pad retainer and the bridge may be formed together.Preferably, the inboard pad retainer is a separate piece that isattached to the bridge. The inboard pad retainer may remain staticduring a brake apply with respect to the bridge of the caliper. Forexample, the entire caliper may move and thus the inboard pad retainermay move with the caliper; however, the inboard pad retainer remainsstatic relative to the bridge. The inboard pad retainer may have 1 ormore fingers, 2 or more fingers, or 3 or more fingers. The inboard padretainer may form an angle with the bridge, the piston bore axis, orboth. The inboard pad retainer may form substantially a right angle withthe bridge, the piston bore axis, or both. The inboard pad retainer mayform the same angle with the bridge, the piston bore axis, or both asPreferably, the inboard pad retainer may be attached to the rail of thebridge by a rail attachment.

The one or more piston bores may be located on an inboard side, anoutboard side, or both of the caliper. The caliper may include one ortwo piston bores on an inboard side and one or two piston bores on anoutboard side. Preferably, the caliper includes only one piston bore onah inboard side of the caliper. More preferably, the caliper is free ofopposing pistons, piston bores, or both. The caliper may be free ofpistons, piston bores or both on opposing sides of the bridge. Eachpiston bore houses a piston that axially extends along the piston boreaxis into contact with a brake pad and moves the brake pad into contactwith a rotor so that a brake apply is created. The brake pad may befixed to the piston, thus, the piston and brake pad may move togetheraxially along the piston bore axis to create a friction force. If one ormore pistons are used, each piston may be moved by a different device.Preferably, each piston may be moved by the same device. The device tomove the piston may be connected to the piston bore, part of the pistonbore, or a combination of both. The device to move the piston may belocated proximate to or directly to each piston bore.

The device to move the piston may be a fluid. The fluid may beintroduced info the piston bore so that as the pressure of the fluidincreases the piston is displaced by the fluid. The fluid may beintroduced into the piston bore via a fluid inlet in the piston bore.The fluid inlet may be located at any location on the piston bore sothat as fluid is added into the piston bore during a brake apply thepiston moves. The fluid inlet, preferably, is located in the piston boreat an end of the piston so that as fluid enters the piston bore thefluid pushes the end of the piston so that a brake apply is created.

The device to move the piston may be an electric drive. The electricdrive may be any electric operated device that moves the piston upon anapplication of power. The electric drive may have a shaft that is incommunication with the piston so that during a brake apply the shaftpushes the piston and brake pad into the rotor, and during a brake offthe motor allows the shaft to free float, the motor retracts the shaftafter a brake apply, or both. The electric drive may be free of a pistonand may directly move the brake pads.

The device to move the piston may be a cable actuation device. The cableactuation device may be any device that upon tensioning, releasingtension, or both of a cable a piston moves. The cable actuation devicemay include a cable having a eyelet, a barrel, a loop, a crimp, or acombination thereof for connection to a lever that may be actuatedduring a brake apply so that the lever moves the piston and creates abraking force. The device to move the piston may be located proximate toa shoulder of the caliper, the piston bore, on a support device orknuckle, or a combination thereof.

The shoulder may foe any part of the caliper that attaches the caliperto a support device. The shoulder may be a unitary part of the caliper.The shoulder may attach to a piston bore, a bridge, or both. Theshoulder may have any shape and configuration so that the caliper isattached to a knuckle, a support device, or both. The shoulder may formsubstantially a right angle with the bridge, the piston bore axis, orboth. The bridge and shoulder may have a cantilever attachment. Forexample, the bridge may be connected to the shoulder on one end so thatthe bridge extends and is supported only by the shoulder. The calipermay have one large shoulder that forms a mating relationship with aknuckle, a support device, or both. Preferably, the shoulder iscomprised of two or more bodies. The two or more bodies may be locatedproximate to each other. Preferably, the two or more bodies are spacedapart so that an adjoining portion of a support device may extendbetween the two or more bodies to form a connection. The two or morebodies may have any configuration so that the caliper and the knuckle,the support device, or both form a connection with sufficient strengthso that the caliper may be used to produce a braking force. The two ormore bodies may be spaced apart so that the bodies have sufficientstrength to withstand radial forces applied during a brake apply, toassist in created a braking force, or both. The two or more bodies ofthe caliper, preferably, are located on the outside of the caliper sothat the portions of the knuckle, the support device, or both fitbetween the two bodies of the caliper. The connection between the two ormore bodies and the knuckle, the support device, or both may be anyconfiguration so that the braking device may produce a braking forceduring maximum stress (e.g., during an emergency stop), may withstandforces during a maximum stress brake apply, or both. The connectionbetween the caliper and the support device may have a home position.

The home position may be any position so that an axis parallel to theknuckle when viewed along a side view (i.e., viewed in the directionalong an axis of the one or more fasteners) may form an angle with aplane substantially parallel to the bridge of the caliper, the pistonbore axis, or both. For example, the axis may run parallel to theknuckle, one or more bodies, or both and the axis forms an angle withthe piston bore when the caliper is in the home position. The axisparallel to the knuckle, when viewed from a side view, may besubstantially a right angle with the bridge, a plane parallel to thebridge, the piston bore axis, or a combination thereof in the homeposition. The axis parallel to the knuckle may align with the shoulder,one or more bodies, or both when the caliper is in the home position.The home position may be an angle of about 85 degrees or more, about 88degrees or more, about 89 degrees or more preferably about 90 degrees ormore. The home position may be about 95 degrees or less, preferablyabout 93 degrees or less, or about 92 degrees or less. The home positionmay form the same angle when the brake pads are new and when the brakepads are worn. The home position and the running position may be thesame position may form the same angle between the axis parallel to theknuckle when viewed along a side view and the bridge, a plane parallelto the bridge, the piston bore axis, or a combination thereof. During abrake apply the movement of the piston may move the caliper so that abraking force is created.

The caliper may move from the home position to a brake-on positionduring a brake apply. The caliper may move a first distance when thebrake pads are new and a second distance when the brake pads are worn,thus, the angle may be vary based upon the condition of the brake pads.The caliper may move forward during a brake apply so that the anglebetween the axis parallel to the knuckle, when viewed along a side view,and the bridge of the caliper, a plane substantially parallel to thebridge of the caliper, the piston bore axis, or a combination thereof isabout 90 degrees or less. The caliper may move backwards during a brakeapply so that the angle between an axis parallel to the knuckle, whenviewed in a side view, and the bridge of the caliper, a planesubstantially parallel to the bridge of the caliper, the piston boreaxis, or a combination thereof is 90 degrees or more. The angle during abrake apply may be about 90 degrees or more, preferably about 91 degreesor more, mere preferably about 92 degrees or more. Depending on thecondition of the brake pads the angle may be about 95 degrees or more,about 100 degrees or more, or about 105 degrees or more. Preferably, theangle during a brake apply may be about 140 degrees or less, about 125degrees or less, or about 115 degrees or less. The connection betweenthe two or more bodies and the knuckle, the support device, or both maybe made by any device that will fixedly secure the caliper to theknuckle, the support device, or both.

One or more fasteners may foe used to connect the shoulder to theknuckle, the support device, or both. The shoulder, the knuckle, thesupport device, or a combination thereof may have one or more attachmentfeatures so that the caliper may be fixedly attached to an adjacentstructure. The attachment features may be any feature that may assist inattaching a shoulder to a support device. Preferably, the attachmentfeature is one or more through holes, one or more partial holes, or bothlocated in the adjoining structures (e.g., shoulder, bodies, knuckle,support device, or a combination thereof) so that one or more fastenersmay be placed into the adjoining attachment feature and secure the partstogether. The attachment feature and the fasteners may form aninterference fit such that once the fastener is press fit info theattachment feature the fastener will be retained in the attachmentfeature and connect the parts together. The attachment features in theshoulder, the knuckle, the support device, or a combination thereof mayfoe the same size, different sizes, or both. The attachment features inthe shoulder, the knuckle, the support device, or a combination thereofmay be the same size as the one or more fasteners, larger than thefasteners, or both. The attachment feature may foe any shape, size,configuration, or a combination so that the shoulder may be attached toa support structure. The attachment features may be smooth, threaded,tapered, oval, round, square, or a combination thereof. The fastenersmay be any fastener that, when placed through a shoulder (i.e., one ormore bodies) and an adjacent knuckle, support device, or both, attachesthe shoulder to the adjacent structure. The fasteners may form athreaded connection, may extend though the attachment features and forma pinned connection, may be a bolted connection, or a combinationthereof. The fastener may form a connection that has sufficient strengthso that the fastener, the shoulder, the knuckle, the support device, ora combination thereof may withstand a maximum stress braking event(i.e., an emergency brake apply). The fastener may form any connectionso that the caliper may move during a brake apply, brake off, or acondition therebetween. The fastener may fee used with a spacer.

The spacer may be any configuration so that the spacer reduces the gapbetween the fastener and the respective part of the caliper, the spacerprovides a pre-load on a body, the spacer prevents the fastener fromloosening, or a combination thereof. The spacer may be made of anymaterial that performs the functions discussed herein. The spacer may bemade of metal, plastic, rubber, a synthetic material, a naturalmaterial, or a combination thereof. The spacer may prevent the caliperfrom moving from side to side along the knuckle, the support device, orboth (i.e., radially relative to the rotor). The spacer may allow thecaliper to move in an outboard direction, an inboard direction, or both.

The caliper may move any distance so that the caliper creates a brakingforce during a brake apply, the brake pads and rotor have minimalcontact during running, disc thickness variation (DTV) is minimized,brake torque variation (BTV) is minimized, or a combination thereof. Asdiscussed herein disc thickness variation is the distance between theinner face and outer face of a rotor when measured at differenttangential locations along the rotor. Stated another way DTV is thechange in thickness between the faces of the rotor as the thickness ismeasured along the faces of the rotor. As discussed herein brake torquevariation (BTV) is defined as the different in torque output as therotor rotates to different positions, the torque being unrelated todifferences in input pressure of the piston. Stated another way BTV is achange in pressure on the rotor as the rotates due to changes inthickness of the rotor, wobble of the rotor, or both. The caliper maymove towards the outboard side, the inboard side, or both. The totaltravel distance of the caliper may be any distance so that both brakepads contact the rotor to create a braking force. The total traveldistance of the caliper may be sufficient so that both brake padscontact the rotor during a brake apply, and so that during running thebrake pad are substantially free of contact with the rotor. The calipermay have a total travel distance of about 1 mm or more, about 2 mm ormore, about 3 mm or more, or about 4 mm of more. The caliper may have atotal travel distance of about 10 mm or less, about 8 mm or less, orabout 8 mm or less. The total travel distance may be the distance oftravel from a furthest distance the caliper may move in the outboarddirection to the furthest distance the caliper may move in the inboarddirection.

The shoulder, the knuckle, the support device, or a combination thereofmay form a connection with a mating relationship. The connection mayhave one or more gaps between the shoulder, the knuckle, the supportdevice, or a combination thereof. The one or more gaps may be any sizeand shape so that the caliper may rotate around the fastener during abrake apply, a brake off, or a condition therebetween. The one or gapsmay be any size and/or at any location so that during a brake apply,brake off, or a condition therebetween the caliper may move so that thebrake pads are substantially aligned with the rotor so that the faces ofthe brake pads do not contact the rotor during a brake off and the facesof the brake pads contact the rotor along their length during a brakeapply. The one or more gaps may be located between the bottom of the oneor more bodies, one or more shoulders, or both and the top of theknuckle, the support device, or both; the one or more gaps may belocated between a side of a body, a shoulder, or both and the knuckleand/or the support device; or both. The one or more gaps may be any sizeso that the caliper may move during a brake apply; a brake off, or acondition therebetween. The one or more gaps may be 0.001 mm or more,about 0.01 mm or more, or about 0.1 mm or more. The one or more gaps maybe about 3 mm or less, about 2 mm or less, or about 1 mm or less. Thebodies, shoulder, knuckle, support device, or a combination thereof maybe shaped so that the one or more gaps have a configuration such as aflat, a contoured, a rounded, a square, or a combination thereof. Forexample, one side of the gap may have a “U” shape and the opposing sideof the gap may be generally flat so that as the caliper rotates thecaliper contacts an upper portion of the “U” and further rotation isprevented. The opposing surfaces of the gap may have a substantiallyco-planar relationship so that the caliper rotates a slight amountbefore the two surfaces contact and prevent further rotation. Theopposing surfaces of the gap may be matches so that they have a similarshape. The one or more gaps may be free of any tabs.

Preferably, the one or more gaps may include one or more tabs. The tabsmay be any device that may assist in locating or manipulating thelocation of the caliper by rotating the caliper, aligning the caliper,stabilizing the caliper, centering the caliper on a fastener,maintaining a gap, retracting the caliper from a brake on position to arunning position, or a combination thereof. The one or more tabs may bestatic, may bias, may be flexible, may be rigid, may act to seal thegap, or a combination thereof. The tabs may be used in conjunction withone or more bushings that seal around the one or more fasteners that maybe located anywhere so as to maintain the location of the caliper. Theone or more tabs may act as a spacer between the caliper and a supportdevice, a knuckle, or both. The one or more tabs may be located at anylocation along the connection points. The one or more tabs may belocated between a shoulder, a knuckle, a support device, a fastener, abushing, or a combination thereof so that the tab provides a loadbetween the two opposing parts, align the opposing pads, or both. Theone or more tabs may work in conjunction with one or more of the partsof the braking system discussed herein so that the brake pads move intocontact with a rotor and create a friction force. The tab includes abody.

The body may include a sleeve and a deflection arm. A fastener mayextend through the body and a sleeve so that the fastener connects thecaliper to a support device and/of a knuckle. The sleeve may projectaway from the body. The sleeve may project out so that the sleeve fitswithin an attachment feature of a caliper, a shoulder, a knuckle, asupport device, a body, or a combination thereof. The sleeve may be anysize and shape so that the sleeve fits within an attachment feature andso that a fastener may extend into and through the sleeve. Preferably,the sleeve extends into a knuckle and/or a support device and a fastenerextends through the tab so that the tab separates the fastener from theknuckle and/or support device. The sleeve may be round, oval, square, acomplementary shape to a fastener and/or an attachment feature, or acombination thereof. The sleeve may have any length so that the sleeveprovides support to the fastener, the caliper, the support device, theknuckle, or a combination thereof so that the tab assists in positioningthe caliper. The sleeve may have a continuous diameter when measured atany point along the circle. The sleeve may include a portion where thediameter of the sleeve is larger. For example, the sleeve may have ahousing where the sleeve extends out to accommodate a fastener and/or alocking tab. The sleeve may include one or more housing features foraccommodating one or more flares.

The flares may be located at any location along the length of thesleeve. The flares may be located at any location on the tab so that theflares assist in maintaining the position of the tab relative to thefastener, the knuckle, the support device, the caliper, or a combinationthereof. The flares may assist in fitting the tab in an attachmentfeature, fitting a fastener in the attachment feature, fitting the tabto the fastener, or a combination thereof. Preferably, the flares fitthe tab to the knuckle, the support device, or both so that the positionof the tab is maintained and the caliper rotates around the tab. The oneor more flares may be any device that assists in holding the tab to thefastener, the knuckle, the support device, the caliper, or a combinationthereof. The one or more flares may be a portion of the sleeve thatextends towards the fastener, the knuckle, the support device, thecaliper, or a combination thereof so that the tab fits within theknuckle and/or support bracket and a fastener fits within the tab. Theone or more flares may create a friction fit, an interference fit, mayresist pull back, may resist rotation of the tab, or a combinationthereof between the tab and the support device, the knuckle, thefastener, or a combination thereof. The one or more flares may elongatethe tab so that the tab fits within an elongated attachment feature. Forexample, the one or more flares may extend a portion of the sleeve sothat the sleeve contacts an attachment feature at multiple locations sothat the sleeve substantially fills the attachment feature and so thatthe tab may accommodate a non-elongated fastener. The flares may be anyshape and size so that the flares adjust the shape of the sleeve to theshape of the attachment feature. The flares may be shaped so that theflare extends outside of the sleeve so that the flare is a raisedportion that extends above the sleeve. The flares may be shaped so thatthe flares create a recess and/or a pocket on the inside of the sleeve.The flares may be a portion of the sleeve that is extended above thesleeve so that the extension fits an elongated attachment feature. Theflare may be any portion that is shaped so that the tab fits in anelongated attachment feature (e.g., an ellipse, oval, rectangle, thelike or a combination thereof). Preferably, the flares are a portionthat enables the tab to fit within an elongated attachment feature andsimultaneously accommodate a standard shaped fastener (e.g., a circularfastener). The sleeve may include one or more, two or more, three ormore, or even four or more flares. Preferably, the sleeve includes twoflares located on opposing sides of the sleeve (i.e., 180 degreesapart). The one or more flares and sleeves may be located below adeflection arm.

The deflection arm may be any part of the tab that extends out from thebody. The deflection arm may be any device that flexes during rotationof the caliper so that the deflection arm assists in moving the caliper.The deflection arm may assist in moving the caliper during a brakeapply. Preferably, the deflection arm assists in moving the caliper to ahome position when a brake apply is complete. The deflection arm may fitwithin any gap between the knuckle, the support device, and the caliperso that during movement of the caliper relative to the support deviceand/or the knuckle the tab moves, resists movement, or both. Thedeflection arm preferably extends over a portion of a knuckle and/or asupport device and under a portion of the caliper so that duringmovement of the caliper the caliper contacts the deflection arm so thatonce a brake apply is complete the deflection arm assists in moving thecaliper to the home position. A portion of the knuckle and/or supportdevice may be sandwiched between the sleeve and the deflection arm. Thedeflection arm may be substantially parallel to the sleeve. Thedeflection arm may be planar (i.e., extend within one plane). Thedeflection arm may be stepped. For example, the deflection arm mayextend in a first plane and then angle down into a second plane so thatthe deflection arm places pressure on the fastener, the caliper, theknuckle, the support device, or a combination thereof when thedeflection arm is in the home position, during a brake apply, or acondition therebetween. The deflection arm may be angled up or down. Thedeflection arm may have any orientation so that the deflection armassists in reorienting the caliper after a brake apply so that the brakepads and rotor are free of contact during running.

The rotor may be any rotor that when contacted by brake pads create abraking force. The rotor may be any rotor with two opposing brakingsurfaces so that brake pads may contact the opposing braking surfaces tocreate a friction force.

The brake pads may be any brake pad that may be useful in creating afriction force. The brake pads may include a pressure plate and a liningmaterial. The brake pads may be free of a pressure plate. The liningmaterial may have sufficient strength so that the lining material mayattach the brake pads to a pad retainer. The inboard brake pad and theoutboard brake pad may be made of the same material, different material,or a combination thereof. Preferably, the inboard brake pad and theoutboard brake pad are made of different materials. More preferably, theoutboard brake pad may be made of a harder material than the inboardbrake pad. One brake pad may be made of a material that wears slowerthan the opposing brake pad. The lining material of the brake pads havea ratio of wear. For example, one brake pad lining material may wearabout 1 mm and the opposing brake lining material may wear about 2 mmduring an equal braking distance (i.e., 1:2). The ratio of wear of thelining material may be about 1:1, about 1:2 or more, about 1:2.5 ormore, about 1:3 or more, or about 1:3.5 or more. The ratio of wear ofthe lining material may be about 1:10 or less, about 1:8 or less, about1:6 or less, or about 1:5 or less.

An air gap may exist between the brake pads and the rotor duringrunning. The air gap may be formed by any known method such asretraction of the piston and related brake pad by a seal in a sealgroove. The air gap may be created by compression and/or deflection andsubsequent decompression and/or deflection of the brake pad, the rotor,or both. The brake system as discussed herein may be free of “springback” caused by bushings, boots, pad, clips, compressibility of thebrake pad linings, the rotor, or a combination. The air gap may becreated by the brake pads contacting the rotor, and the runout of therotor moving the brake pads, the caliper, the pad retainers, or acombination thereof so that the air gap is created and contact betweenthe brake pads and the rotor is minimized during running, brake off, orboth.

FIG. 1 illustrates a caliper 2 directly attached to a knuckle 100. Thecaliper 2 includes a piston bore 4 housing a piston 6 (not shown). Thepiston bore 4 includes a fluid inlet 12 for introducing fluid during abrake apply so that the piston 8 (not shown) moves. The caliper 2 has abridge 8 including a rail 10. The bridge 8 terminates on one end at anoutboard pad retainer 30 for holding an outboard brake pad 32 (notshown). The caliper 2 is attached to the knuckle 100 via a shoulder 40.The shoulder 40 as illustrated includes two body portions 42. Fasteners44 extend through the body portions 42 so that the caliper 2 isconnected to the knuckle 100. A spacer 48 separates each fastener fromthe shoulder 40.

FIG. 2 illustrates a caliper 2 including an electric drive 80 for movingthe piston 6 (not shown) along the piston bore axis 18 during a brakeapply.

FIG. 3 illustrates a caliper 2 including a cable actuation device 70 formoving the piston 6 (not shown) along the piston bore axis 18 when acable 72 pulls the lever arm 74 via a barrel attachment 76.

FIG. 4 illustrates a cross-sectional view across cut I-I of FIG. 2. Asillustrated the shoulder 40 is attached to the knuckle 100 via twobodies 42 each being connected by a fastener 44 including a spacer 46. Agap exists between an upper portion of the knuckle 100 and the shoulder40 between the two body portions 42. A space exists between each bodyportion 42 and the knuckle 100. The gap has a width (G) and the spacehas a width (S) so that the caliper 2 can rotate around the fasteners 44during a brake apply, a brake off, or a condition therebetween.

FIG. 5 illustrates a close up view of one fastener 44 of FIG. 4. Thefastener 44 extends into a body 42 of the caliper and includes a spacer46 between a head of the fastener 44 and the body 42.

FIG. 6 illustrates a cross-sectional view of a body 42 cut along lineII-II of FIG. 3. The body 42 as illustrated includes art attachmentfeature 48 that is oblong so that the fastener 44 is smaller than theattachment feature 48 and the body portion 42 can move back and forth asindicated by the arrows 50 during a brake apply, brake off, or acondition therebetween.

FIG. 7 illustrates a caliper 2. The caliper 2 includes a piston bore 4having a piston 6. A bridge 8 connects a piston bore 4 to an outboardpad retainer 30. The outboard pad retainer 30 includes a pad retainerattachment 28 for attachment to an outboard brake pad 32. The bridge 8includes an inboard pad retainer 20 having a rail 10 on the outside ofthe bridge 8 and a rail attachment 24 for attaching the inboard brakepad 22 to the rail 10 via a rail attachment 24. The caliper 2 isattached to a support device 100 via a shoulder 40 with two bodies 42.The bodies 42 each include a fastener 44 that extends through eachrespective body 42 into the support device 100.

FIG. 8 illustrates one embodiment of a brake pad as is illustrated inFIG. 7. The inboard brake pad 22 includes a rail attachment 24 on eachside of the inboard brake pad 22. The inboard brake pad 22 includes abrake pad projection 14 for attachment to an outboard pad retainer 30(not shown) that has a pad retainer attachment 26 (not shown). Theinboard brake pad 22 includes a brake pad locator 18 for aligning theinboard brake pad 22 with a piston (not shown).

FIG. 9 illustrates a rear perspective view of a caliper 2. The caliper 2includes an inboard brake pad 22 and an outboard brake pad 32 with arotor 90 therebetween. The inboard brake pad 22 has a rail attachment 24that attaches to a mil 10 on the bridge 8 of the caliper 2. The caliper2 during a brake apply rotates around the fastener 44 in the direction50 during a brake apply and a brake off.

FIGS. 10A-10C illustrate the caliper 2 of the present teachings during abrake release and a brake apply. FIGS. 10A and 108 illustrate brakeapplies with new brake pads 102 and worn brake pads 104 respectively,and the change in the body position during a brake apply. Asillustrated, the caliper 2 of FIG. 10A includes new brake pads 102contacting the rotor 90 so that the caliper is substantially free ofrotation around the fastener 44 in the shoulder 40, to create a brakeapply. The caliper 2, during a brake apply with new brake pads 102 ispositioned so that the piston bore axis 18 forms substantially a rightangle with a plane 108 parallel the knuckle 100 when viewed from a sideview.

FIG. 10B illustrates the caliper 2 during a brake apply when the caliper2 includes worn brake pads 104. As illustrated, during a brake apply thecaliper 2 rotates around one or more fasteners 44 in a shoulder 40 sothat the inboard brake pad 22 and the outboard brake pad 32 contact arotor 90. The caliper 2 during a brake apply moves so that the pistonbore axis 18 forms an angle (β) with a plane 108 along the knuckle 100when viewed from a side view. As illustrates, the inboard brake pad 22is connected via an inboard pad retainer 20.

FIG. 10C illustrates the caliper 2 in a brake off position. The caliper2 rotates around the fastener 44 in the shoulder 40, and the caliper 2moves so that the piston bore axis 18 forms an angle (α) with a plane108 parallel to the knuckle 100, when viewed from a side view. Thecaliper 2 during a brake off rotates so that an air gap 110 is createdbetween the inboard brake pad 22, the outboard brake pad 32, and therotor 90. As illustrated the air gaps 110 is the smallest in theopposing corners 112 of the brake pads due to the rotation of thecaliper 2 around a fastener 44.

FIG. 11 illustrates a tab 80 located between a knuckle 100 and ashoulder 40 of a caliper. A fastener 44 extends through one body 42through a first tab 80, the knuckle 100, a second tab 80, and extendsinto a second body 42. The tab 80 aligns the shoulder 40 of the caliperrelative to the knuckle 100 so that alignment is maintained before,during, and after a brake apply.

FIG. 12 illustrates a tab 80. The tab 80 includes a deflection arm 82that is spaced apart from a sleeve 88. The sleeve 86 extends into theknuckle 100 (not shown) and the deflection arm 82 extends over theknuckle 100 (not shown) so that during a brake apply, running, or acondition therebetween the deflection arm 82 assists in maintaining thecaliper (not shown) in position and/or returning the caliper to a homeposition. The sleeve 88 includes two flares 84 for fitting the tab 80into an attachment feature 48 (not shown) and for attaching the tab 80to a fastener 44 (not shown). The tab 80 includes a body 88 that thedeflection arm 82 and the sleeve 88 extend from.

Any numerical values recited herein include all values from the lowervalue to the upper value in increments of one unit provided that thereis a separation of at least 2 units between any lower value and anyhigher value. As an example, if it is stated that the amount of acomponent or a value of a process variable such as, for example,temperature, pressure, time and the like is, for example, from 1 to 90,preferably from 20 to 80, more preferably from 30 to 70, it is intendedthat values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. areexpressly enumerated in this specification. For values which are lessthan one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 asappropriate. These are only examples of what is specifically intendedand all possible combinations of numerical values between the lowestvalue and the highest value enumerated are to foe considered to beexpressly stated in this application in a similar manner.

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes. The term “consisting essentially of” to describe a combinationshall include the elements, ingredients, components or steps identified,and such other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations of elements, ingredients, components or stepsherein also contemplates embodiments that consist essentially of theelements, ingredients, components or steps. By use of the term “may”herein, it is intended that any described attributes that “may” beincluded are optional.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps.

It is understood that the above description is intended to beillustrative and not restrictive. Many embodiments as well as manyapplications besides the examples provided will be apparent to those ofskill in the art upon reading the above description. The scope of theteachings should, therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent applications and publications, areincorporated by reference for all purposes. The omission in thefollowing claims of any aspect of subject matter that is disclosedherein is not a disclaimer of such subject matter, nor should it beregarded that the inventors did not consider such subject matter to bepart of the disclosed inventive subject matter.

I claim:
 1. A device comprising: a. a caliper comprising: i. one or morepiston bores housing a piston that is extendable along a piston boreaxis; ii. an outboard pad retainer; iii. a bridge; and iv. a shoulderhaving one or more attachment features forming a through hole in theshoulder; wherein the caliper is configured to be attached directly to aknuckle of an automobile via the shoulder and one or more fasteners; andwherein the one or more attachment features are larger in the pistonbore axis direction than the one or more fasteners so that the caliperwhen attached to the knuckle is capable of being displaceable along thepiston bore axis.
 2. The device of claim 1, wherein the device is freeof a support bracket.
 3. The device of claim 1, wherein the caliper isfree of attachment to a support bracket.
 4. The device of claim 1,wherein the outboard pad retainer is a unitary piece that extends fromthe bridge.
 5. The device of claim 1, wherein the bridge includes a railso that an inboard brake pad moves along the rail during a brake apply,a brake off, or a condition therebetween.
 6. The device of claim 1,wherein the shoulder includes at least two bodies and the at least twobodies are spaced apart so that the knuckle extends between the at leasttwo bodies and the shoulder attaches the caliper to the knuckle.
 7. Thedevice of claim 6, wherein the fastener extends through the at least twobodies and the knuckle so that the caliper is attached to the knuckle.8. The device of claim 1, wherein a gap is located between the knuckleand the shoulder so that the caliper rotates during a brake apply, abrake off, or a condition therebetween.
 9. The device of claim 8,wherein one or more tabs are located between the one or more fastenersand the shoulder, the knuckle, or both so that the one or more tabsprovide a load on the caliper, the knuckle, or both and align thecaliper with the knuckle.
 10. The device of claim 9, wherein the one ormore tabs include: a. a body; b. a deflection arm; and c. a sleevehaving one or more flares; wherein the deflection arm and sleeve extendfrom the body, and the one or more fasteners extend through the sleeveand the one or more flares so that the one or more tabs accommodate thefastener and connect the device to the knuckle, and the one or more tabsfit within an attachment feature of the knuckle.
 11. The device of claim1, wherein the outboard pad retainer includes a brake pad with a liningmaterial and an inboard pad retainer that includes a brake pad with alining material and the lining materials of the brake pads aredifferent.
 12. The device of claim 11, wherein the lining material ofthe outboard brake pad is harder than the lining material of the inboardbrake pad.
 13. The device of claim 1, wherein the one or more pistonbores include an electric drive for moving the pistons.
 14. The deviceof claim 1, wherein the one or more piston bores include a fluid thatmoves the piston during a brake apply.
 15. The device of claim 1,wherein in the one or more pistons include a cable actuation devicethat, moves the piston during a brake apply.
 16. The device of claim 8,wherein the attachment features are smooth, oval, or both.
 17. Thedevice of claim 1, wherein a spacer is located between the fastener andthe shoulder so that the spacer provides a pre-load on the shoulder. 18.A disc brake system comprising: a. a caliper comprising: i. one or morepiston bores horsing a piston; ii. an outboard pad retainer; iii. abridge having a rail so that an inboard brake pad moves along the railduring a brake apply, a brake off, or a condition thereof; iv. aninboard pad retainer; v. a shoulder including one or more attachmentfeatures forming an oblong through hole that extend through theshoulder; and vi. one or more tabs; b. a rotor connected to a knuckle ofan automobile, wherein the bridge extends over the rotor; wherein thecaliper is attached directly to the knuckle via the shoulder and one ormore fasteners and the caliper is free of attachment to a supportbracket; wherein the one or more tabs are located between the caliperand the knuckle; and wherein the caliper when attached to the knucklevia the one or more fasteners extending through the oblong through holein the one more attachment features is capable of rotationally movingand moving along an axis of the rotor.
 19. The device of claim 18,wherein a gap is located between the knuckle and the shoulder so thatthe caliper is rotationally movable during a brake apply, a brake off,or a condition therebetween; one or more tabs are located between theone or more fasteners and the shoulder, the knuckle, or both so that theone or more tabs provide a load on the caliper, the knuckle, or both andalign the caliper with the knuckle; and wherein the one or more tabsinclude: a. a body; b. a deflection arm; and c. a sleeve having one ormore flares; wherein the deflection arm and sleeve extend from the body,and the one or more fasteners extend through the sleeve and the one ormore flares so that the one or more tabs accommodate the fastener andconnect the device to the knuckle, and the one or more tabs fit withinan attachment feature of the knuckle.
 20. A device comprising: a calipercomprising: i. one or more piston bores housing a piston; ii. anoutboard pad retainer; iii. a bridge; iv. one or more fasteners; v. ashoulder that is configured to be attached directly to a knuckle of anautomobile via the shoulder and the one or more fasteners; vi. one ormore tabs including:
 1. a body;
 2. a deflection arm; and
 3. a sleevehaving one or more flares; wherein the deflection arm and sleeve extendfrom the body, and the one or more fasteners extend through the sleeveand the one or more flares so that the one or more tabs accommodate theone or more fasteners and connect the caliper to the knuckle, and theone or more tabs fit within an attachment feature of the knuckle;wherein the one or more tabs are located between the one or morefasteners and the shoulder, the knuckle, or both so that the one or moretabs provide a load on the caliper, the knuckle, or both and align thecaliper with the knuckle; and wherein a gap is located between theknuckle and the shoulder so that the caliper is capable of rotatingduring a brake apply, a brake off, or a condition therebetween.